Charging Roll Adhesive Layer Roughness for Molding Accuracy
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Solution Overview
Problem
Charging rolls used in electrophotographic image forming apparatuses face challenges in achieving both excellent adhesiveness between the conductive elastic layer and adhesive layer and dimensional stability, as high adhesiveness often leads to reduced dimensional accuracy due to scratching during extrusion molding or injection molding processes.
Innovation Solution
A charging roll with a cylindrical base member having a metal-containing surface, a conductive adhesive layer containing a halogen atom-containing resin with surface roughness Rz between 0.5 μm to 8 μm, and a conductive elastic layer made of halogen atom-containing rubber, which improves adhesiveness and maintains dimensional accuracy by adjusting the surface roughness and friction coefficient of the adhesive layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conductive elastic layer is formed on an adhesive layer through extrusion molding or injection molding to achieve excellent adhesiveness, then adhesiveness is improved, but dimensional accuracy deteriorates due to scratching during the molding process
Solution Approach 1:
The invention changes the surface roughness parameter of the adhesive layer to a specific range (Ra: 0.5-8 μm, Rz: 1.0-20 μm) to optimize both adhesiveness and dimensional accuracy. This parameter adjustment prevents excessive scratching during extrusion molding while maintaining strong adhesion for the conductive elastic layer.
Solution Approach 2:
The invention uses a composite structure combining an adhesive layer with controlled surface roughness and a conductive elastic layer. The adhesive layer contains specific additives that modify surface properties, creating a composite material system that simultaneously achieves high adhesiveness and dimensional stability without scratching during molding.
2Strength
If the surface roughness of the adhesive layer is increased to improve adhesion, then adhesiveness is improved, but dimensional stability deteriorates due to increased scratching during extrusion molding
Solution Approach 1:
The invention optimizes the surface roughness parameters (Ra: 0.5-8 μm, Rz: 1.0-20 μm) of the adhesive layer to find the optimal balance point. This controlled roughness range provides sufficient adhesion while preventing excessive scratching during extrusion molding, thereby maintaining dimensional stability.
Solution Approach 2:
The invention applies different surface quality characteristics to different aspects of the adhesive layer: the surface roughness is specifically controlled for the interface with the conductive elastic layer to maximize adhesion, while the overall dimensional stability is maintained through the optimized roughness range that prevents molding-induced scratching.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a charging roll with enhanced adhesiveness and dimensional stability, ensuring consistent performance and preventing scratches during the molding process, thereby maintaining the accuracy and longevity of the charging roll.
Implementation Method 1
a conductive elastic layer that is disposed to be brought into contact with the outer peripheral surface of the conductive adhesive layer
Data Source
AI summary
A charging roll includes a cylindrical base member that has a metal-containing surface, a conductive adhesive layer that includes a halogen atom-containing resin and has surface roughness Rz in a range of 0.5 μm to 8 μm on an outer peripheral surface side on the base member, and a conductive elastic layer that is disposed to be brought into contact with the outer peripheral surface of the conductive adhesive layer and includes a halogen atom-containing rubber.